Foam-based fasteners

Abstract

In one embodiment of the present invention, an article has a mechanical fastener and configured is to be worn by a user. The article comprises a body portion configured to be worn by a user. The body portion may include a fibrous landing layer wherein the fibrous landing layer comprises a plurality of fibers. The body portion may also include a foam layer, such that the foam layer has a first surface comprising a plurality of free-stranding struts adapted for engaging at least a portion of the plurality of fibers of the landing layer. The foam layer and fibrous landing layer are capable of being engaged with a Shear Resistance of about 100 grams of force or greater per square centimeter and a Peel Resistance of about 50 grams or less of force per square centimeter.

We claim: 
     
       1. An article having a mechanical fastener and configured to be worn by a user, comprising:
 a body portion configured to be worn by a user and including a landing layer wherein the landing layer comprises a plurality of fibers; and, 
 the body portion also including a foam layer, the foam layer having a first surface comprising a plurality of free-standing struts adapted for engaging at least a portion of the plurality of fibers of the landing layer. 
 
     
     
       2. The article as set forth in  claim 1 , wherein the plurality of free-standing struts of the foam layer have diameters of about 50 microns or less. 
     
     
       3. The article as set forth in  claim 1 , wherein the plurality of free-standing struts of the foam layer have heights of about 500 microns or less. 
     
     
       4. The article as set forth in  claim 1 , wherein the plurality of fibers of the landing layer are selected from the group consisting of natural fibers, synthetic fibers, and mixtures thereof. 
     
     
       5. The article as set forth in  claim 1 , wherein fibers of the landing layer form loops. 
     
     
       6. The article as set forth in  claim 5 , wherein at least a portion of the free-standing struts are engageable with at least a portion of the loops in the landing layer. 
     
     
       7. The article as set forth in  claim 5 , wherein loops in the landing layer have a titer of about 4.5 dtex or less. 
     
     
       8. The article as set forth in  claim 1 , wherein the fibers of the landing layer form openings. 
     
     
       9. The article as set forth in  claim 8 , wherein at least a portion of the free-standing struts are engageable with at least a portion of the openings in the landing layer. 
     
     
       10. The article as set forth in  claim 8 , wherein openings in the landing layer have a diameter of about 0.5 μm or greater. 
     
     
       11. The article as set forth in  claim 1 , wherein the foam layer comprises a foam material selected from the group consisting essentially of: melamines; polyadehydes; polyurethanes; polylsocyanurites; polyolefins; polyvinylchloride; epoxy foams; ureaformaldehyde; latex foam; silicone foam; fluoropolymer foams; polystyrene foams; and, mixtures thereof. 
     
     
       12. The article as set forth in  claim 1 , wherein the foam layer comprises an open-celled foam material. 
     
     
       13. The article as set forth in  claim 12 , wherein the open-celled foam material has a density of about 0.006 g/cc to about 0.1 g/cc. 
     
     
       14. The article as set forth in  claim 8 , wherein at least a portion of the foam layer comprises a plurality of hooks wherein the plurality of hooks are engageable with the openings of the landing layer. 
     
     
       15. The article as set forth in  claim 5 , wherein at least a portion of the foam layer comprises a plurality of hooks wherein the plurality of hooks are engageable with the loops of the landing layer. 
     
     
       16. The article asset forth in  claim 1 , wherein:
 the body portion includes a stretch member extending outwardly therefrom, wherein the stretch member is formed of a necked bonded laminate material; and, 
 the stretch member includes a tab member extending outwardly therefrom, wherein the tab member is formed of a spunbond/meltblown/spunbond material, and the foam layer is attached to the spunbond/meltblown/spunbond material. 
 
     
     
       17. The article as set forth in  claim 1 , wherein the article is a diaper. 
     
     
       18. The article as set forth in  claim 1 , wherein the foam layer and landing layer are capable of being engaged with a Shear Resistance of about 100 grams of force or greater per square centimeter. 
     
     
       19. The article as set forth in  claim 18 , wherein the foam layer and landing layer are further capable of being engaged with a Peel Resistance of about 50 grams or less of force per square centimeter. 
     
     
       20. An article having a mechanical fastener and configured to be worn by a user, comprising:
 a body portion configured to be worn by a user; 
 the body portion including a landing layer comprising a plurality of fibers, wherein at least a portion of the fibers form openings in the landing layer; and, 
 the body portion also including a foam layer, wherein the foam layer has a first surface comprising a plurality of free-standing struts capable of engaging the plurality of openings of the landing layer. 
 
     
     
       21. The article as set forth in  claim 20 , wherein the plurality of free-standing struts of the foam layer have diameters of about 50 microns or less. 
     
     
       22. The article as set fort in  claim 20 , wherein the plurality of free-standing struts of the foam layer have heights of about 500 microns or less. 
     
     
       23. The article as set forth in  claim 20 , wherein the plurality of fibers of the landing layer are selected from the group consisting of natural fibers, synthetic fibers, and mixtures thereof. 
     
     
       24. The article as set forth in  claim 20 , wherein at least a portion of the free-standing struts are engageable with at least a portion of the openings in the landing layer. 
     
     
       25. The article as set forth in  claim 20 , wherein openings in the landing layer have a diameter of about 0.5 μm or greater. 
     
     
       26. The article as set forth in  claim 20 , wherein the foam layer comprises a foam material selected from the group consisting essentially of: melamines; polyadehydes; polyurethanes; polyisocyanurites; polyolefins; polyvinylchloride; epoxy foams; ureaformaldehyde; latex foam; silicone foam; fluoropolymer foams; polystyrene foams; and, mixtures thereof. 
     
     
       27. The article as set forth in  claim 20 , wherein the foam layer comprises an open-celled foam material. 
     
     
       28. The article as set forth in  claim 27 , wherein the open-celled foam material has a density of about 0.006 g/cc to about 0.1 g/cc. 
     
     
       29. The article as set forth in  claim 20 , wherein at least a portion of the foam layer comprises a plurality of hooks wherein the plurality of hooks are engageable with the openings of the landing layer. 
     
     
       30. The article as set forth in  claim 20 , wherein:
 the body portion includes stretch member extending outwardly therefrom, the stretch member is formed of a necked bonded laminate material; and, 
 the stretch member includes a tab member extending outwardly therefrom, wherein the tab member is formed of a spunbond/meltblown/spunbond material, and the foam layer is attached to the spunbond/meltblown/spunbond material. 
 
     
     
       31. The article as set forth in  claim 20 , wherein article is a diaper.